Public Funding for Malin Marine Consultants Limited

**MariLight2** is aimed at transforming shipbuilding and marine fabrication sectors in the UK, developing and demonstrating **Smart Design** and **Large Scale Additive Manufacturing (LSAM)** technologies that will revolutionise the traditional design and build process. MarilLight, the CMDC2 feasibility project, concluded that topology optimisation could reduce the weight of ship structural components by up to 48% with no impact on performance, and widespread application of these applications could **reduce the the total weight of a typical steel ship by 13%**, with the associated through-life fuel and emission reductions The Malin Group, Caley Ocean Systems, and BAE will showcase its efficacy in a low-risk, pre-production environment through functional component testing. Backed by a consortium of 8 partners and a select Steering Group, the project ensures that outcomes remain pertinent and aligned with industry demands while expediting certification and qualification for a sustainable, data-led, and digitally enabled large-scale manufacturing trajectory. Upon successful completion, **MariLight2** is expected to inject £300M into the UK economy, generate over 100 jobs directly, and create indirect employment opportunities for 5,000 individuals nationwide before 2030\. Anticipated deliverables include 50% production productivity improvements, reliability, and export potential for large-scale manufacturing, and operational cost reductions---such as delay and manual handling---by up to 90%. The innovative thrust of **MariLight2** lies in its comprehensive approach. By integrating circular design principles and leveraging data-rich, automated production, it optimises manufacturing processes. Combined with LSAM methodologies, this results in streamlined, localised, and flexible production pathways. The incorporation of digital product passports delivers a cradle-to-grave traceability approach, enhancing end-of-life strategies and minimising waste. **MariLight2** is set to significantly reduce steel usage in manufacturing, with like-for-like reduction of 31% facilitating potential annual savings of 14 million tonnes in global shipbuilding. It will counterbalance an estimated 12 million tonnes of CO2e, in line with the UK's 2050 net-zero target. The **MariLight2** methodology is expected to curb scrap production by 25%, shrink manufacturing emissions by 37%, and enable 90% of parts to have circular opportunities. Through data traceability, integrated manufacturing pathways, and digital product passports, it aims to augment productivity by 50% and boost reliability by 60%. With key end-users such as Malin, Caley Ocean Systems, and BAE Systems, supported by a diverse consortium of specialists, **MariLight2** meets the industry's call for innovation head-on. It not only aligns with Maritime UK National Priorities, but also the broader global sustainable development agenda, marking it as a **genuinely transformative endeavour**.

The marine transport industry contributes towards 940m tonnes of CO2 emission annually(2.5% of the global greenhouse emissions). The International Maritime Organisation (IMO) is committed to reducing emissions from international shipping and is working to phase them out. Its initial strategy identifies technological innovation as integral to achieving the overall ambition, whilst introducing rules requiring ships to be designed and built in an energy-efficient fashion, measured by the [Energy Efficiency Design Index][0] (EEDI). In the UK there is considerable emphasis on reducing emissions to reach greener maritime transport solutions, with the stated target of decarbonising all sectors to achieve 'net zero' by 2050\. This will be accomplished by progress in many aspects of design and operation, but the starting point will be **minimising ship weight and power demand**, **improving underlying vessel efficiency** so that new propulsion technologies will have the most significant impact. From a practical perspective, it is critical to address inefficiencies in existing design and manufacturing processes that prevent industry growth, making best use of Industry 4.0 developments to increase process automation, improve quality, reduce manual activity, and enhance working conditions. The MariLight project will achieve this, providing the marine industry with initial steps to move from conventional, manual fabrication that requires labour-intensive work, to an automated and flexible manufacturing route, with potential to deliver complex designs through **topology optimisation design and Large-scale Additive Manufacturing (LSAM).** Expected benefits include: \***13% vessel weight saving,** \***global fleet savings of 7.7m tonnes of steel,** \***90% manufacturing lead time reduction,** \***60% production fuel/energy savings,** \***20% reduction in production time.** This feasibility study will demonstrate a transformative design and manufacturing process route that reduces current shipbuilding manufacturing environmental impact by **60%, providing \>10% emission savings throughout a standard 30-year service life.** Led by **Malin Group**, MariLight will generate a robust Business Case, detailing features such as lightweighting, CO2 reduction, and cost benefits to inform not only the marine industry, but also other industry sectors. This will be achieved by introducing topology-optimised design and regulatory frameworks to produce **lighter shipbuilding components** utilising LSAM techniques. The extensive expertise from the consortium also composed of **Altair Engineering, BAE Systems, Lloyd's Register, and the National Manufacturing Institute Scotland (NMIS)**, the project will permit achieving reliable outcomes that can be exploited by different markets (e.g., automotive, Oil & Gas), providing the UK with opportunities to be more competitive and diversified, whilst creating jobs in highly skilled areas. [0]: https://www.imo.org/en/OurWork/Environment/Pages/Technical-and-Operational-Measures.aspx